Repair and assembly tool

ABSTRACT

A closing tool is provided for assembling an outer panel of a tailgate, decklid, door or the like to an interior panel. The closing tool may work in conjunction with an opening tool which operates to separate the outer panel from the interior panel at the hem flange. The closing tool includes a receptacle for receiving a partially open hem flange and the interior panel and a shaft. The shaft further defines a base at its lateral end for receiving an impact from a hammer or the like. Upon impact, the receptacle surrounds the partially open hem flange and the interior door panel thereby closing the hem flange.

CROSS REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional application serial no. 60/272,927, filed Mar. 2, 2001.

FIELD OF THE INVENTION

[0002] The present invention relates to the field of repair, service, and/or assembly tools.

BACKGROUND OF THE INVENTION

[0003] Vehicles generally include doors, hoods, deck lids, and/or tailgates which each have one unitary outer skin of sheet metal. The outer panel of sheet metal is joined to a second inner reinforcing panel of sheet metal by hemming a flange over and along the edge the door, hood or deck lid.

[0004] Hemming the unitary outer skin of sheet metal to the vehicle components is generally a time-intensive and labor-intensive process. Repair shops must generally replace the outer vehicle panels where the panels are damaged or where corrosion has formed at the hem flange.

[0005] In the assembly of the doors, hoods, deck lids and the like, the first stage of the hemming process includes nesting an inner panel within an outer panel fixture on an anvil die on a base of a prehemming machine. Once the assembly has been fixtured, a tool called a hemming steel engages and bends an edge of the outer panel to an acute angle with respect to the inner panel. The second stage of the hemming process involves transferring the assembly to a second hemming machine which completely bends the prehemmed edge of the outer panel over the edge of the inner panel to secure and attach the panels together as a unitary structural member for assembly on a vehicle. An adhesive is applied between the inner panel and the folded-over edge of the outer panel. Occasionally, corrosion or damage may occur to the vehicle requiring the opening of the outer door panel in the repair process.

[0006] The repair process for vehicle doors, hoods, deck lids, tailgates and the like is generally a time-intensive and labor-intensive due to the construction of the doors, hoods, deck lids, and tailgates. In order to replace an outer panel, a user must grind the outer panel at the edge of the door near the hem flange. Upon grinding the outer panel, the outer panel is removed in pieces and must be completely replaced. However, this process not only destroys an outer panel which may be repairable, but takes a significant amount of time and effort.

[0007] Consequently a need has developed for a repair system and method to easily remove and re-install the panels of a vehicle.

SUMMARY OF INVENTION

[0008] It is a principal object of the present invention to provide a repair system and method to easily remove and reinstall the outer panels of a vehicle.

[0009] It is yet another object of the present invention to provide a closing tool to close a hem flange onto a vehicle door without scratching the paint on the outer panel.

[0010] It is yet another object of the present invention to reduce the installment time for outer door panel to an interior door panel.

[0011] It is still another object of the present invention to provide a method for re-installing an outer vehicle panel to an interior vehicle panel without damaging the outer vehicle panel.

[0012] In accordance with the above objects and other objects and features of the present invention, a tool is provided to easily re-install or install an outer vehicle panel to an interior door panel. Specifically, the tool of the present invention allows a user to close the hem flange on vehicle doors, tailgates and the like without incurring damage to the outer panel thereby saving time and money. The closing tool is preferably, but not necessarily, used in conjunction with an opening tool which is operative to separate the outer panel from the interior panel at the hem flange. The opening tool includes a mounting arm, a blade, a shoulder and optionally, a scratch resistor. The opening tool is preferably but not necessarily mounted to an air gun. The blade is integral to the shoulder and the mounting arm. The blade is operative to lift the hem flange away from the inner panel. The shoulder is operative to maintain the position of the blade as the blade travels down the hem flange. The blade and the shoulder join at the mounting arm and are integral to each other. The shoulder may further include a scratch resistor to prevent paint removal from the outer skin as the shoulder abuts the outer skin and travels against the outer skin. The scratch resistor may consist of a reinforced nylon plastic component which is seated within a recess defined by the shoulder. The scratch resistor may also consist of a coating on the shoulder.

[0013] The closing tool, which may be used in conjunction with the opening tool, includes a receptacle and a handle. The receptacle further includes a recess which is defined by an upper projection and a lower projection which are both substantially planar. The recess is operative to receive an open or partially open flange and the inner panel. Upon receiving the open or partially open hem flange and the inner panel in the recess, the hem flange is closed and sealed against the inner panel. The upper projection and the lower projection are integral to one another and are joined at the base of each of the projections.

[0014] As those skilled in the art will recognize, the embodiments of this invention may vary depending upon the specific requirements of a vehicle. Accordingly, the particular size and shape of the mounting arm, blade, shoulder, and scratch resistor of the opening tool in addition to the upper projection, lower projection, connecting member and handle of the closing tool may vary, depending on the particular application.

[0015] The above objects and other objects, features, and advantages of the present invention are more readily understood from a review of the attached drawings and accompanying specification.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016]FIG. 1 is a perspective view of a first side of the opening tool.

[0017]FIG. 2 is a perspective view of a second side of the opening tool.

[0018]FIG. 3 is a top-view of the opening tool inserted onto an already closed weld flange.

[0019]FIG. 4 is a side view of the opening tool inserted onto a closed weld flange.

[0020]FIG. 5 is a perspective view of a first side of the closing tool.

[0021]FIG. 6 is a perspective view of a second side of the closing tool.

[0022] FIGS. 7 is a perspective view of a hem flange inserted within the closing tool.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0023] With reference to FIGS. 1 and 2, the opening tool 10 is shown. The opening tool includes a blade 10, a mounting arm 14, scratch resistor 16, and a shoulder 18. The mounting arm 14, as shown in FIG. 1A, is operative to mount the opening tool 10 to an air gun 20.

[0024] The blade 12, the mounting arm 14, and the shoulder 18 are integral to each other and may, but not necessarily, be formed of 4140 Steel. In operation, the blade 12 of the opening tool 10 is inserted between the door inner 26 and hem flange 24 as shown in FIGS. 3 and 4. As the opening tool 10 and air gun 20 travel along the edge of the door 26 at the hem flange 24, the hem flange 24 is opened away from the inner panel or door inner 26. The shoulder 18 of the opening tool 10 maintains the position of the blade 12 under the hem flange 24 as the opening tool 10 travels along the hem flange 24.

[0025] The shoulder 18 of the opening tool 10 may further include a scratch resistor 16. The scratch resistor 16 may, but not necessarily, be a nylon-reinforced plastic component. Where the scratch resistor 16 is a nylon-reinforced plastic component, the scratch resistor 16 may sit in a recess 28 defined by the shoulder 18 and adjacent to the door panel. The scratch resistor 16 may be removably affixed to the shoulder 18 so as to prevent the opening of paint as the opening tool 10 lifts the hem flange 24. The scratch resistor 16 may be replaced from time to time as the scratch resistor 16 is worn and scratched due to normal use. One alternative to a separate plastic component, the scratch resistor 16 may be made up of a plastic coating 28 around the shoulder 18 to prevent the opening of paint as the shoulder travels against the outer skin or panel 30 of the vehicle. As recognized by those skilled in the art, the scratch resistor 16, which prevents paint removal, may take various forms.

[0026] As shown in FIGS. 1 and 2, the mounting arm 14 may also include a projection 32 to properly seat the opening tool 10 to an air gun 20 or a handle 22. It is preferable but not necessary to mount the opening tool 10 to an air gun 20 to reduce the effort required to raise the hem flange 24.

[0027] Referring now to FIGS. 5 and 6, the closing tool 34 is illustrated. As shown, the closing tool 34 includes a receptacle 36 and a shaft 38. The receptacle 36 is defined by an upper or first projection 40 and a lower or second projection 42. The receptacle 36 is operative to receive an open or partially open hem flange 24 and the door inner or inner panel 26. The first projection 40 and the second projection 42 join at a connecting member 44 and are integral to the connecting member 44. The connecting member may be mounted onto a shaft 38, or in the alternative, may be integral to the connecting member 44 so that a user may manually maintain the position of the closing tool 34. The shaft 38 further includes a base 46 at its lateral end 48 to receive an impact from hammer 52 or the like.

[0028] As shown in FIGS. 5 and 6, the second projection 42 may be longer than the first projection 40 in predetermined areas 48, 50 in order to permit the closing 34 tool to easily receive a partially open hem flange and door inner.

[0029] Referring now to FIG. 7, the closing tool 34 receives the hem flange 24 and the inner panel 26 in the recess 36 between the first projection 40 and the second projection 42. In receiving the hem flange 24 and the inner panel 26, it is preferable to surround the hem flange 24 and the inner panel 26 such that the hem flange 24 and inner panel 26 abut the connecting member 44 upon impact of the hammer 52. As shown in FIG. 7, the manually operated hammer 52 may exert an impact onto the base 46 of the closing tool 34 in order to close the partially open or open hem flange 24.

[0030] While the best modes for carrying out the invention have been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention. The words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and the scope of the invention. 

What is claimed is:
 1. A tool for assembling an outer door panel to an interior door panel, the tool comprising: a receptacle for receiving a partially open outer door panel and the interior door panel; and a shaft integral to the receptacle.
 2. The tool defined in claim 1 wherein the receptacle is substantially planar.
 3. The tool defined in claim 1 wherein the receptacle is defined by a first projection, a second projection and a connecting member wherein the connecting member is integral to the first projection and the second projection.
 4. The tool defined in claim 2 wherein the substantially planar receptacle is defined by a first projection, a second projection and a connecting member wherein the connecting member is integral to the first projection and the second projection.
 5. The tool defined in claim 2 wherein the receptacle is integral to the shaft.
 6. The tool defined in claim 2 wherein the receptacle is mounted onto the shaft.
 7. The tool defined in claim 1 wherein the receptacle is integral to the shaft.
 8. The tool defined in claim 1 wherein the receptacle is mounted onto the shaft.
 9. The tool defined in claim 1 wherein the lateral end of the shaft defines a base for receiving an impact thereby allowing the receptacle to surround and close the hem flange.
 10. The tool defined in claim 1 wherein the tool is formed of nylon-reinforced injection molded plastic.
 11. An assembly tool for attaching an outer door panel to an interior door panel at the hem flange, the tool comprising: a receptacle defined by a first projection and a second projection wherein the first projection is integral to the second projection; and a shaft.
 12. The assembly tool defined in claim 11 wherein the assembly tool is formed of nylon-reinforced injection molded plastic. 